Aerosol dispenser having a wall-surrounded valve actuator button



3,161,330 DED 2 Sheets-Sheet 2 Dec. 15, 1964 P. H. SAGARIN ETAL AEROSOL DISPENSER HAVING A WALLSURROUN VALVE ACTUATOR BUTTON Original Filed April 8, 1960 United States Patent This invention relates to small pressurized dispensing or aerosol devices of the type intended to be held in the hand and to be hand actuated for eifecting discharge of 'the aerosol substance.

The present application is a continuation of our application Serial No. 20,890, filed April 8, 1960, now abandoned and entitled Aerosol Device.

As a general rule, aerosol devices of the above type involve internal pressures of between 40 and 75 pounds per square inch and heretofore such devices have utilized containers formed of metal cans or cups having metal sealing and closure ferrules for the reason that it was considered necessary to have the relatively high tensile strength of sheet metal in order to safely contain the pressurized substance. Such metal containers usually involved a number of separate pieces or components which required assembly operations, and also required surface treatment or finishing, whereby a fairly appreciable cost was involved.

The present invention particularly deals with aerosol devices which may be thought of as low-pressure, small volume aerosols as compared with the conventional type outlined above, since the average volumes handled are small fractions of those encountered with multi-part metal-can type aerosols, and since the average pressures are in a lower range of values, as for example between 20 and 35 pounds per square inch. However, the inven tion is not limited only to these particular devices. In producing such low pressure small volume devices the invention obviates the above disadvantages and drawbacks involved with containers of the larger, higher-pressure type aerosol devices, and one object or" the invention is to provide an improved small low-pressure dispensing aerosol device of the type indicated and method of producing .the same, wherein the dispenser or container cost is brought down to the lowest possible figure.

Another object of the invention is to provide an improved aerosol dispensiug device as above set forth, which is small, compact and attractive in appearance, easy I to operate, and reliable in use.

- mistakable indication of the direction of spray, positive retention of the actuator button, and the providing of a seal in conjunction with a plastic valve housing but also at the same time constituting an effective container which Elhlfidb Patented Dec. 15, 1964 ice is in effect seamless and at all times holds the aerosol substance substantially without leakage.

Further, the invention provides a surprisingly new procedure wherein a thermoplastic container is partially cold-filled with a chilled or cold, liquified aerosol substance and thereafter closed and sealed by spin-welding a thermoplastic closure to the container, such operation providing the necessary heat to melt the cooperable plastic parts despite the presence of the cold aerosol charge. The spin welding is not only quick and economical, but also effective to produce the required seal, and proof against leakage over an extended period of use.

Accordingly, features of the invention include the provision of an economically producible one-piece plastic molded container having a portion which serves as part of the valve seat, the producing of a plastic pressureresistant aerosol container which has no metal ferrules or rubber sealing gaskets associated with metal ferrules but which is in effect seamless and of surprisingly great strength, the producing of such container which is hermetically sealed by a spin-welded plastic closure piece having a plastic-to-plastic seal with the container walls, all devoid of foreign metallic or rubberlike materials, a container as above which guides and also guards the valve button and retains the same against removal, and which carries the plastic valve housing and provides therewith an effective seal, all the while reducing costs through elimination of separate parts, elimination of assembly operations, finishing operations and the like while at the same time not sacrificing reliability and uniformity of operation.

In the illustrated embodiments of the invention, the container is essentially tubular and slightly conical, with the bottom end of largest diameter, said end in accordance with the method being closed bya spun-in closure which fuses to the body to become essentially integral therewith. The smaller diameter, top end is open and holds Within it the actuator button, which has an orifice fitting extending through and held captive in a slot in the side wall of the container. Below the top edge the container has a transverse sealing wall in the form of an inverted cup, in the hollow of which the plastic valve housing is carried. The transverse wall has an opening through which the plastic valve stem extends, and further constitutes part of a valve seat means cooperable with said stem. Preferably the plastic valve housing is retained in the plastic cup-wall by a press fit and by interlocking elements. From the lower portion of the valve housing a dip tube extends to the bottom of the container, said tube also aiding in the retention of the housing in the transverse Wall.

While the illustrated embodiments reveal several detailed constructions, the invention is not limited thereto but instead embraces broader concepts as set forth in the appended claims.

In the drawings:

FIG. 1 is an axial sectional View of an aerosol device embodying the invention.

FIG. 2 is a view partly in side elevation and partly in axial section of an aerosol device in accordance with the invention, showing a modified form adapted for dispensing in inverted position.

As seen in FIG. 1, the relative sizes of the valve construction, actuator button thereof and the container for the aerosol substance clearly indicate that the container 3 V is relatively small and nearer to a vial size than it is to the standard or conventional aerosol device utilizing metal containers and ranging from 6 ounces to 16 ounces, net weight. In contrast with such larger containers, the container of the present aerosol device is intended to hold much smaller quantities of aerosol substance, as for example quantities in the neighborhood of one ounce and even less. tion may be considered as of such a small size that it approaches the practical minimum, which at the present time is considered to be below .an ounce. Further, in keeping with the relatively small size, the present'aerosol device involves a lower pressure range, as for example a pressure range of between 20 and 35 pounds per square inch as compared with the appreciably higher pressure Thus, the aerosol device of the'present invenrange of 40 to 75 pounds per square inch usually employed with metal containers in sizes of from 6 to 16 ounces.

By the present invention the aerosol device as illustrated herein is characterized bya novel and advantageous, one- ..piece, unitary plastic container structure which is preferably formed by molding processes, the said structure being constituted wholly of plastic substance such as nylon or Delrin (synthetic fiber-forming polymeric amide) or similar material and being particularly entirely devoid of metal parts or components.

As shown, the container structure, indicated by the numeral 10, is in the form of a small tubular vessel having a slightly conical configuration with the largest diameter at its bottom end 12, the side walls of the container from there sloping preferably to a smaller diameter at the top,

open end 14. g By the invention there is provided a novel surprisingly different methodof producing a plastic aerosoldevice.

In carrying out this method the bottom end 12 of they "cohtaiiieris completely closed and sealed after-cold-filling of the container by a transverse bottom wall 16 which is bonded and fused to the bottom side wall ofthe con- -tainer by being spun against the latter in a manner such :that theffrictional heat generated melts the plastic substance at the joint and causes such substance to fuse, resulting '(in effect) in the bottom wall '16 being integral with the body of the container. 'In the appended claims this type of attachment is characterized as a spin-weld seal. Prior to the spinning-in and fusion of the bottom 'wall, the cooperable or mating surfaces of the bottom 16 and the side wall 12 may have an interlocking or interfitting configuration, as illustrated. However,- it will be understood that after the bottom has been spun against and fused to the side wall of the container there no longer exists a distinct line of demarkation between these components, but instead there exists a zone or area at which.

the plasticsurface have become fused with each other.

Thus, in effect,ithe bottom and sides-cf the container. are

- is devoid of distinct joints and of alli foreign metallic and rubber like materials. I

By the present invention, the upper open end 14 of the v ment.

button 18 is held captive in the upper open end 14 of 28 has an enlarged end or head portion 34 occupying recesses 36 in the side edges of the notch or slot 32. By such construction anadditional guiding connection is had, while at the same time the button 18 is held captive and the head portion 34 of the'orifice fitting 28 does not unduly project or rotrude from the side of the container 10.

. The novel plastic container structure of the invention further comprises an upper cupped transverse wall 40 which is integral with the body of the container, being preferably molded therewith as one piece. As seen in the figure, those portion 14 of the side walls of the container 10 which are located above the transverse top Wall 40 are tapered in thickness to eliminate an undercut condition,.whereby thecontainer structure may be removed from a simple mold cavity Without difliculty or involve- Preferablv, as shown in the figure, the top transverse wall 40 is in the form of an inverted cup, having a generally flat top portion 42, substantially cylindrical side walls 44, and an annular lip or Web portion 46 which joins the side walls 44 of the cup-like formation to'the side walls of the container 10; The cup-like formation comprising the top transverse wall 40 is also preferably formed with an inwardly extending annular detent rib 48 disposed in the side walls 44 and having a relatively small height whereby there will be no ditficulty in removing the core piece which forms the inside of the-container.

In accordance with the invention, the upper transverse wall 40 is disposed below and reinforced by the top end 14 to minimize its [spreading radially when the vessel is under pressure, and is arranged to constitute a part of a valve-seat means for" cooperation with the valve stem 20, being also arranged to carry a plastic valve housing 50 which is shown as having a formation suited for molding from plastic material. For example, the housing 50 may be made of resilient or flexible plastic substance such as polyethylene or similar formulations. Theflat top portion 42 of the wall 40 has a central aperture 52, through which the'valve stem 22 passes, said stem having an enlargment ,or shoulder 54 constituting avalve, which is engageable with a valve disc .56 disposed within the cuplike formation of the top transverse wall 40.

The valve housing 50 hasa central bore, in which the valve stem 22 is disposed, together with a valve return spring 58 engaging at its upper end the enlargement 54' and at its lowerend an internal shoulder 60. The lower end of the valve stem 22;has a flat 62 and passes within the annular shoulder 60, whereby'the latter together with the stem constitutes a metering valve which closes when the valve stem 20 is depressed-to efiect a separation of the valve shoulder '54 from the. valve seat disc 56.

The valve stem 22 has a side opening 64 communicating with the central bore (shown by dottedlines in the figure) in the upper portion of the stem 22, whereby the aerosol substance under pressure in the metering chamber 66 may discharge through the button 18 and orifice container 10 constitutes both a guide and a guard for an' actuator button ,18- which is. carried by the uppermost portion 20 of a plastic valve stem 22. The button 18 has a channel 24, 26 providing a passage for the aerosol substance being discharged, said substance passing through a center boreiin-the-valve stem- 22. A sliding fit is provided between the push-button 18 and the open end 14 of the container 10, whereby the button" is vertically movt able in the top end of the container while at the same time being guided and prevented from having an appreciable lateral or horizontal movement.

Further, in accordance with the invention, the push fitting 28 at the time that the side opening 64 becomes disposed below the valve disc 56in response to downward movement of the button 18 and the valve stem 22.

The discharge metering action of the valve stem 22, in

- conjunction with the plastic valve h ousing 50 is also'disclosed and explained in detail in the copending application of Philip H. Sagarin filed January 20, 1960, Serial No. 3,619, new Patent No. 3,054,556 and entitled Valve and Closure Construction for Aerosol Devices. Accordingly, further explanation "of the action of the. metering valvemechanism is not given herein, since such valve per sedoes not constitute thepresent invention. 5

The valve housing50 at its upperend has a outwardly projecting annular mounting shoulder or flange 7% arranged to be press-fitted into the cup-like formation of the upper transverse wall 40 of the container, thereby to secure in place the valve disc 56. Preferably, as shown, the detent bead 48 engages the lower surface of the mounting flange 70, as shown, to provide an interlocking engagement, thereby to more effectively secure the valve housing 50 in its position. During the assembly of the valve housing 50 to the wall 40 the mounting flange 70 is forced upward past the detent bead 48, these parts together with the side wall 44 of the cup-like formation yielding to permit proper positioning of the valve housing in the wall, as shown.

At its lower end the valve housing 50 carries a dip tube 72 which extends to a point closely adjacent the bottom wall 16 of the container. The dip tube 72 is preferably made of a flexible and resilient plastic substance such as polyethylene, and due to its short length as compared with its diameter and wall thickness, in somewhat stiff, to an extent suflicient to prevent dislodgement of the valve housing 50. The clip tube 72 may be press-fitted in the lower portion of the valve housing as indicated.

It will be noted that the container It does not have or require the usual metal ferrule or rubber seal associated therewith, but instead has an integral all-plastic top wall closure in the Wall sections 42, 44 and 46, and this is an important feature of the invention.

The areosol device as above described and provided by the invention has important advantages. For one thing, it is extremely economical to fabricate and produce, thereby enabling an appreciable reduction in the cost of the container and valve structure. A minimum number of separate components are involved in its fabrication, and the assembly operations are reduced to a minimum. Moreover, no finishing or surface finishing or similar operations are necessary. The container is entirely devoid of metal parts, and accordingly there is not the problem of resistance to the corrosive action of aerosol substances. The container may be fabricated in simple mold cavities, as a single unitary molded piece, and provides a number of different and distinct functions which include not only the support of the valve mechanism by the upper transverse wall 40, but also the function of constituting a part of the valve seat means, in conjunction with the valve disc 56. The upper open end 14 of the housing 10 guides the valve actuator button 18, and also by virtue of the wall 14 surrounding a large portion of the button, it constitutes a guard for the same, preventing accidental actuation of the button. The sloping end edge 39 of the Wall portion 14 facilitates actuation of the button by the finger. Moreover, by the provision of the slot 32 and the orifice fitting 23, which may be of a distinctive and different color from that of the container 19, there is provided an unmistakable indication of the direction of spray. And, the orifice fitting 28 in conjunction with the wall 14 serves to positively retain the actuator button in the open end portion 14 of the container structure. The upper transverse wall 49 is effectively sealed to the valve housing 50 by virtue of the interposition of the valve disc 56, thereby preventing undesired leakage past the exterior of the valve housing. By virtue of the spun-in bottom wall 16 which is fused and made integral with the container body, the container structure constitutes an effective seamless vessel which at all times holds the aerosol substance without appreciable leakage. It is further seen that the aerosol device is small, compact and attractive in appearance, easy to operate, and reliable in use.

In FIG. 2 is shown an aerosol device illustrating a modification adapted for operation in inverted position. Parts similar to those already described have the same numerals. The structure of FIG. 2 differs in that the valve housing 56a is cut off short, at a point adjacent the fiatted tip 62 of the valve stem, and the dip tube is dis pensed with and not used. Otherwise the structures are similar.

Variations and modifications may be made within the scope of the claims, and portions of the improvement may be used without others.

We claim:

1. An aerosol device comprising in combination a pressure-tight plastic container all the walls of which are integral with each other, said container having an integral transverse wall at its top, provided with a through opening; valve seat means within the container adjacent said opening of the transverse wall; a valve stem extending through said opening, having a valve shoulder engageable with said valve seat means to close the said opening against egress of aerosol substance from within the container; a tubular plastic housing within the container, disposed around that portion of the valve stem which is located inside of the top transverse wall, said housing having at its lower end an opening to admit aerosol substance around the said valve stem portion and being engaged with and carried by the container adjacent the valve seat means, said means being confined by the housing; a transverse, pressure-tight, plastic closure wall at the bottom of and integral with the container whereby the latter constitutes a closed vessel; a dip tube carried by the lower end of the housing and extending downward therefrom to a point adjacent the closure wall at the bottom of the container, said tube being relatively short and rigid and serving to maintain the housing in position engaged with the container, the top transverse wall of the container being in the form of an inverted cup and said housing being received in the hollow of the cup and being locked against removal therefrom by the dip tube.

2. The invention as defined in claim 1, in which the cup has side wall portions located inwardly of and spaced from upper peripheral portions of the container.

3. The invention as defined in claim 2, in which the housing is of resilient plastic substance, and in which the side portions of the top transverse wall have inwardly projecting integral molded means interlocking with the housing to retain the latter in position.

4. The invention as defined in claim 3, in which the side portions of the transverse top wall have a relatively thin section and may be expanded outward slightly to admit the said housing.

5. A hand-held, pressurized, finger-operated dispensing device comprising, in combination, an all-plastic molded pressure-resistant vessel entirely devoid of metal, said vessel having a single thickness tubular side wall structure and a cupped, single thickness transverse, radially deformable top wall and closure which is integral with the side wall structure, said vessel being adapted to contain a pressurized substance intended to be dispensed; means carried by the transverse top wall of the vessel, providing a discharge passage for said substance through said top wall; manually-operable valve means connected with said discharge passage to control the flow of said substance therethrough, said vessel having a tubular open top end located above the transverse top wall and constituted of substantially strai ht, single thickness, upward continuations of the tubular side wall structure of the vessel, said tubular open top end extending for an appreciable distance above said cupped transverse top wall and above the upper portion of the tubular side wall structure, and effecting a substantial reinforcement thereof to prevent radial spreading of the top wall including the cupped portion thereof and the side wall structure, said valve means being disposed below said transverse top wall; and an actuator button for operating the valve means, said bu ton being movably mounted within said open top end of the vessel and having side bearing surfaces disposed adjacent and engaged with said single thickness upward continuations whereby the buttin is guided for vertical movement.

- 7 V 8 6. The invention as defined in claim 5, in which the 2,848,854 8/58 Redd 5337 upper rim of the open top end is sloping with respect to 2,863,699 12/ 5 8 El'ser. a plane normal to the axis of the container, and is dis- 2,879,818 3/ 59: Root. posed at a level which is below the top of the actuator 2,931,540 4/ 6 0 Meshherg' 239- 573 X button. 5 2,942,748 6/60 Andersen.

7 References Cited by the Examiner 3,002,871 10/ 61 Tr'an 1m et al. 2 29-470 X UNITED STATES PATENTS 3,003,662, 10/61 M I V V 2 V 3,060,656 10/62 Cohen et al. 5337 ggggggi 222215 3,081,917 3/63 Quercia hm. 222-394 83,872 '3 2,781,950 2/57 Pritchard 222-7394 10 3 0 4/6 Meshberg 222 394 X 2,835,418 5/58 Manetti 222-394 RAPHAEL M. LUPQ'fir'z'mary Examiner. 

1. AN AEROSOL DEVICE COMPRISING IN COMBINATION A PRESSURE-TIGHT PLASTIC CONTAINER ALL THE WALLS OF WHICH ARE INTEGRAL WITH EACH OTHER, SAID CONTAINER HAVING AN INTEGRAL TRANSVERSE WALL AT ITS TOP, PROVIDED WITH A THROUGH OPENING; VALVE SEAT MEANS WITHIN THE CONTAINER ADJACENT SAID OPENING OF THE TRANSVERSE WALL; A VALVE STEM EXTENDING THROUGH SAID OPENING, HAVING A VALVE SHOULDER ENGAGEABLE WITH SAID VALVE SEAT MEANS TO CLOSE THE SAID OPENING AGAINST EGRESS OF AEROSOL SUBSTANCE FROM WITHIN THE CONTAINER; A TUBULAR PLASTIC HOUSING WITHIN THE CONTAINER, DISPOSED AROUND THAT PORTION OF THE VALVE STEM WHICH IS LOCATED INSIDE OF THE TOP TRANSVERSE WALL, SAID HOUSING HAVING AT ITS LOWER END AN OPENING TO ADMIT AEROSOL SUBSTANCE AROUND THE SAID VALVE STEM PORTION AND BEING ENGAGED WITH AND CARRIED BY THE CONTAINER ADJACENT THE VALVE SEAT MEANS, SAID MEANS BEING CONFINED BY THE HOUSING; A TRANSVERSE, PRESSURE-TIGHT, PLASTIC CLOSURE WALL AT THE BOTTOM OF AND INTEGRAL WITH THE CONTAINER WHEREBY THE LATTER CONSTITUTES A CLOSED VESSEL; A DIP TUBE CARRIED BY THE LOWER END OF THE HOUSING AND EXTENDING DOWNWARD THEREFROM TO A POINT ADJACENT THE CLOSURE WALL AT THE BOTTOM OF THE CONTAINER, SAID TUBE BEING RELATIVELY SHORT AND RIGID AND SERVING TO MAINTAIN THE HOUSING IN POSITION ENGAGED WITH THE CONTAINER, THE TOP TRANSVERSE WALL OF THE CONTAINER BEING IN THE FORM OF AN INVERTED CUP AND SAID HOUSING BEING RECEIVED IN THE HOLLOW OF THE CUP AND BEING LOCKED AGAINST REMOVAL THEREFROM BY THE DIP TUBE. 